INTRODUCTION
SP10-1 SPOT WELD is a versatile microprocessor based resistance welding controller featuring sophisticated functions, essential to the modern high technology age with Easy and reliable User Interface with TFT Display 3.2 Inch, key board and LEDs.
The availability of three stage current option (i.e. Pre-Heat, Main Heat, and Post Heat) with upslope makes it suitable for all kinds of spot welding machines.
The INPUT / OUTPUT support provided along with the controller makes it suitable for automation purpose.
SP10-1 SPOT WELD can be operated basically in 2 modes:
1) Power voltage fluctuation compensation mode,
2) Constant current control with secondary feedback.
Power Voltage Fluctuation Mode:
In this mode the RMS voltage applied to the welding transformer is kept constant for the primary voltage variation with the source voltage feedback.
Constant Current Control Mode:
In this mode the regulations allow the constant current to be maintained independent of
- Primary voltage variations
- Impedance variation due to
Heating of secondary circuits: as resistance of copper increases with temperature.
Degradation of flexible conductors.
Increase in the contact resistance of the secondary circuit due to oxidation, loosening and contamination of electrodes.
Magnetic losses due to the presence of sheets in the vicinity or in the secondary loop.
SPECIFICATIONS
1) Standard Specifications
- Welding power source: 415 VAC +10 % ,-25 % , 50 Hz
- Control power source : 415 VAC , + 10% , 50 Hz
- Control Method:
1) Secondary current feedback constant current control or
2) Source voltage fluctuation compensation control method by phase angle control with thyristor. - Secondary Constant current control:
a) Control speed: One cycle
b) Initial responding time: Less than 3 cycles. (After power is turned on until current reaches set current 10 %.)
c) Current accuracy: (Secondary constant current control)
a) Within 2 % against 10% welding power source voltage fluctuation
b) Within 2% against 10% load resistance fluctuation.
c) Within 2% against 1% inductive load fluctuation.
- Source voltage fluctuation compensation control a) Control speed: One cycle b) Initial responding time: Less than 2 cycles. c) Current accuracy: Within 3 % against 10% welding power source voltage fluctuation.
- No. of schedules: 10 schedules (5 schedules per valve)
- No. of valves: 2 valves. (Transistor outputs with +24 VDC, 500 mA capacity)
- Setting of timers:
- Current setting range : 5-30 KA , 10 schedules
1) Constant current control mode: current 1,2,3 can be set to 20% to 100% of maximum current setting.
2) Constant voltage mode: current 1,2,3 can be set to 00 - 99 % . - Maximum current setting range: 5 - 40 KA (Common for all schedules) Set to maximum secondary current of welder.
- Current monitor: (Effective only in constant current control mode)
1) Setting of upper limit (+LIMIT) : 00% - 99%
2) Setting of lower limit (-LIMIT) : 00% - 99%
3) Setting of conduction degree (COND . DEG.) : 1-180 degree. If monitor current is out of set range CURR LIMIT error is indicated. Monitor is turned off if set to 00. - Total counter: Preset 0 - 9999, 10 schedule
If the total number of weld counts reaches the preset value, the ‘TTL COUNT OVER’ error indication is given. The buzzer sounds till the counter is reset and the error output is turned on. - Inputs:
1) START signals: Four start signals are available. By setting the DIP SW2, no. of start signals can be decided. (either 2 or 4 start signals)
2) TWO THERMOSTATS: connects to thyristor and Welding Transformer thermostat.
3) WELD ON/OFF: Welding can be possible if this input is closed else sequence is executed without welding.
4) ERROR RESET: Error alarm and error output are reset when this input is closed. - Outputs:
1) VALVE: Two 24 VDC (500 mA) output
2) Spare 24 VDC (500 mA) output
3) END OF HOLD: Relay contact outout indicating end of hold is provided to indicate end of sequence to the external controlling device (e.g.PLC).
4) ERROR OUTPUT: Relay contact output to indicate error condition.
5) TOTAL COUNT OVER: Relay contact output to indicate count over condition. - Memory Backup: By EEPROM.z
- Operating ambient temperature : 0 - 45 C
- Dimensions: 335 mm (H) x 92 mm (W) x 355 mm (D)
- Weight: 7 Kg
1) Squeeze (SQ) : 00 - 99 cycles , 10 schedules
2) Time of Weld 1 (W1) : 00 - 99 cycles , 10 schedules
3) Time of Cool 1 (C1) : 00 - 99 cycles , 10 schedules
4) Time of Upslope (UP) : 0 - 9 cycles , 10 schedules
5) Time of Weld 2 (W2) : 00 - 99 cycles , 10 schedules
6) Time of Cool 2 (C2) : 00 - 99 cycles , 10 schedules
7) Time of Weld 3 (W3) : 00 - 99 cycles , 10 schedules
8) Hold Time (HLD) : 00 - 99 cycles , 10 schedules
9) Off Time (OFF) : 00 - 99 cycles , 10 schedules
FEATURES
- Easy and reliable User Interface with TFT Display 3.2 Inch and key board and LEDs.
- Effective data storage with EEPROM interface for 10 different schedules according to the materials and thickness of the work pieces to be welded.
- For ensuring proper hardware and software working of the controller a watch dog feature has been provided.
- Ensures a stable RMS welding current by secondary constant current control method and power voltage fluctuation compensation control.
- Apart from controlling features for the welding current the controller has the diagnostic features for detection of SCR Short, OVER Temperature, Pressure switch, Water Flow switch, SET Current Limits error detection, NO CURRENT error, POWER SUPPLY check, MEMORY CHECK detection with proper indication / error codes and alarms.
- Fluctuation of current set values can be maintained in + /- LIMITs.
- Conduction angle can also be monitored.
- Availability of 3 stage current option with upslope.
- Total counter to indicate number of welds / jobs.
Creditable Integrity
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Quality Assurance
Ensure first and best of product quality and service
